U.S. patent application number 10/127215 was filed with the patent office on 2002-08-22 for building block with a cement-based attachment layer.
Invention is credited to Baldwin, Robert A..
Application Number | 20020112427 10/127215 |
Document ID | / |
Family ID | 46279106 |
Filed Date | 2002-08-22 |
United States Patent
Application |
20020112427 |
Kind Code |
A1 |
Baldwin, Robert A. |
August 22, 2002 |
Building block with a cement-based attachment layer
Abstract
A building block has a cement-based attachment layer on one or
both exterior surfaces of the block that can receive and hold a
penetrating fastener such as a nail, screw, staple, or the like.
This allows surficial coverings such as wallboard, siding or other
materials to be easily attached to a block wall made of the
building blocks. The block includes substantially semi-cylindrical
concave portions that form a cross-linked structure of channels
when the blocks are assembled into a wall. Once the blocks have
been stacked in place in a wall, grout or other suitable filling
material is poured into the cross-linked structure of channels.
When the filling material hardens, the blocks are locked together.
Surficial covering materials may then be nailed, screwed, or
stapled directly to the attachment layer.
Inventors: |
Baldwin, Robert A.;
(Phoenix, AZ) |
Correspondence
Address: |
MARTIN & ASSOCIATES, LLC
P O BOX 548
CARTHAGE
MO
64836-0548
US
|
Family ID: |
46279106 |
Appl. No.: |
10/127215 |
Filed: |
April 22, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10127215 |
Apr 22, 2002 |
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09610288 |
Jul 6, 2000 |
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6397549 |
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09610288 |
Jul 6, 2000 |
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08953569 |
Oct 17, 1997 |
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6085480 |
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08953569 |
Oct 17, 1997 |
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08852922 |
May 8, 1997 |
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5913791 |
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Current U.S.
Class: |
52/309.4 ;
52/605; 52/606; 52/607 |
Current CPC
Class: |
E04C 1/40 20130101; E04B
2002/0206 20130101; E04B 2/54 20130101; E04B 2/42 20130101 |
Class at
Publication: |
52/309.4 ;
52/605; 52/606; 52/607 |
International
Class: |
E04C 001/00; E04C
002/04; E04B 005/04 |
Claims
I claim:
1. A building block comprising: a first exterior surface; first and
second side surfaces coupled to the first exterior surface; a top
surface coupled to the first exterior surface and to the first and
second side surfaces; a bottom surface coupled to the first
exterior surface and to the first and second side surfaces; a
second exterior surface coupled to the first and second side
surfaces, to the top surface, and to the bottom surface; wherein
the building block comprises a mixture of water, cement, and
expanded polystyrene (EPS) foam beads that have a diameter from
3.18 mm (1/8 inch) to 9.53 mm (3/8 inch).
2. The building block of claim 1 wherein the building block further
comprises a wetting agent.
3. The building block of claim 2 wherein the wetting agent is
selected from the group consisting of water reducers, plasticizers,
and superplasticizers.
4. The building block of claim 2 wherein the water, cement, wetting
agent, and EPS foam beads are in the proportions of: from 68 to 95
liters (18 to 25 gallons) water; from 150 to 190 kg (325 to 425 lb)
cement; from 0.24 to 0.71 liters (1 to 3 cups) wetting agent; and
from 850 to 1400 liters (30 to 50 cubic feet) EPS foam beads.
5. The building block of claim 4 further comprising from 0.06 to
0.18 liter (0.25 to 0.75 cup) air entrainer.
6. The building block of claim 2 wherein the water, cement, wetting
agent, and EPS foam beads are in the proportions of: from 76 to 87
liters ( 20 to 23 gallons) water; from 160 to 180 kg (350 to 400
lb) cement; from 0.35 to 0.59 liters (1.5 to 2.5 cups) wetting
agent; and from 990 to 1,270 liters (35 to 45 cubic feet) EPS foam
beads.
7. The building block of claim 6 further comprising from 0.08 to
0.16 liter (0.33 to 0.67 cup) air entrainer.
8. The building block of claim 2 wherein the water, cement, wetting
agent, and EPS foam beads are in the proportions of: approximately
81.4 liters (21.5 gallons) water; approximately 171 kg ( 376 lb)
cement; approximately 0.47 liters (2 cups) wetting agent; and
approximately 1,0809 liters (38 cubic feet) EPS foam beads.
9. The building block of claim 8 further comprising approximately
0.12 liter (0.5 cup) air entrainer.
10. The building block of claim 1 wherein: each first and second
side surface comprises a substantially semi-cylindrical concave
portion; the top surface comprises a substantially semi-cylindrical
concave portion; and the bottom surface comprises a substantially
semi-cylindrical concave portion; the substantially
semi-cylindrical concave portions forming a cross-linked structure
of substantially cylindrical channels when a plurality of the
building blocks are assembled into a wall.
11. The building block of claim 1 further comprising a cement-based
attachment layer substantially covering at least one of the first
and second exterior surfaces.
12. The building block of claim 11 wherein the cement-based
attachment layer comprises water, cement, and space-occupying
granules having a size of less than 1 mm (0.04 inch) in the
proportions of: from 26 to 38 liters (6.9 to 10 gallons) water;
from 54.4 to 72.6 kg (120 to 160 lb) cement; and from 2.3 to 23 kg
(5 to 50 lb) space-occupying granules.
13. The building block of claim 12 wherein the space-occupying
granules comprise glass microbubbles.
14. The building block of claim 12 wherein the cement-based
attachment layer further comprises from 2.3 to 9.1 kg (5 to 20 lb)
fiberglass strands.
15. The building block of claim 11 wherein the cement-based
attachment layer comprises water, cement, and space-occupying
granules having a size of less than 1 mm (0.04 inch) in the
proportions of: from 29 to 35 liters (7.6 to 9.2 gallons) water;
from 59.0 to 68.0 kg (130 to 150 lb) cement; and from 4.5 to 11 kg
(10 to 25 lb) space-occupying granules.
16. The building block of claim 15 wherein the space-occupying
granules comprise glass microbubbles.
17. The building block of claim 15 wherein the cement-based
attachment layer further comprises from 2.3 to 9.1 kg (5 to 20 lb)
fiberglass strands.
18. The building block of claim 11 wherein the cement-based
attachment layer comprises water, cement, and space-occupying
granules having a size of less than 1 mm (0.04 inch) in the
proportions of: approximately 32 liters (8.4 gallons) water;
approximately 63.5 kg (140 lb) cement; and approximately to 6.8 kg
(15 lb) space-occupying granules.
19. The building block of claim 18 wherein the space-occupying
granules comprise glass microbubbles.
20. The building block of claim 18 wherein the cement-based
attachment layer further comprises approximately 5.4 kg (12 lb)
fiberglass strands.
21. A building block comprising: a first exterior surface; first
and second side surfaces coupled to the first exterior surface,
each first and second side surface comprising a substantially
semi-cylindrical concave portion; a top surface coupled to the
first exterior surface and to the first and second side surfaces,
the top surface comprising a substantially semi-cylindrical concave
portion extending between the first and second side surfaces; a
bottom surface coupled to the first exterior surface and to the
first and second side surfaces, the bottom surface comprising a
substantially semi-cylindrical concave portion extending between
the first and second side surfaces; a second exterior surface
coupled to the first and second side surfaces, to the top surface,
and to the bottom surface; each of the first and second side
surfaces and the top and bottom surfaces comprising a mixture in
the proportions of: approximately 21.5 gallons (81.4 liters) water;
approximately 171 kg ( 376 lb) cement; approximately 0.47 liters (2
cups) wetting agent; and approximately 1080 liters (38 cubic feet)
expanded polystyrene foam beads with a diameter from 3.18 mm (1/8
inch) to 9.53 mm (3/8 inch); a cement-based attachment layer
substantially covering at least one of the first and second
exterior surfaces.
22. The building block of claim 21 wherein the cement-based
attachment layer comprises water, cement, and space-occupying
granules having a size of less than 1 mm (0.04 inch) in the
proportions of: approximately 32 liters (8.4 gallons) water;
approximately 63.5 kg (140 lb) cement; and approximately to 6.8 kg
(15 lb) space-occupying granules.
23. The building block of claim 22 wherein the space-occupying
granules comprise glass microbubbles.
24. The building block of claim 22 wherein the cement-based
attachment layer further comprises approximately 5.4 kg (12 lb)
fiberglass strands.
25. A method for manufacturing a plurality of building blocks
comprising the steps of: assembling a form comprising a bottom
portion having a length and a width, two side portions along the
length of the bottom portion and coupled to the bottom portion, and
two end portions along the width of the bottom portion, the bottom
portion, side portions, and end portions forming sides of an open
box structure; pouring a layer of cement-based attachment layer mix
within the open box structure of the form; compressing the
attachment layer mix in the form to eliminate voids and air pockets
in the attachment layer mix; leveling the attachment layer mix;
pouring a layer of block mix atop the attachment layer mix in the
form; compressing the block mix to eliminate voids and air pockets
in the block mix; leveling the block mix; placing a lid atop the
block mix; allowing the block mix to cure; disassembling the form;
cutting the cured block mix into the plurality of building blocks;
and forming at least one semi-cylindrical channel in each of the
plurality of building blocks.
26. The method of claim 25 wherein the block mix comprises water,
cement, a wetting agent, and EPS foam beads in first
proportions.
27. The method of claim 26 wherein the first proportions of water,
cement, wetting agent, and EPS foam beads comprise: approximately
81.4 liters (21.5 gallons) water; approximately 171 kg ( 376 lb)
cement; approximately 0.47 liters (2 cups) wetting agent; and
approximately 1,080 liters (38 cubic feet) EPS foam beads.
28. The method of claim 27 wherein the block mix further comprises
approximately 0.12 liter (0.5 cup) air entrainer.
29. The method of claim 25 wherein the cement-based attachment
layer mix comprises water, cement, and space-occupying granules
having a size of less than 1 mm (0.04 inch) in the proportions of:
from 26 to 38 liters (6.9 to 10 gallons) water; from 54.4 to 72.6
kg (120 to 160 lb) cement; and from 2.3 to 23 kg (5 to 50 lb)
space-occupying granules.
30. The method of claim 29 wherein the space-occupying granules
comprise glass microbubbles.
31. The method of claim 29 wherein the cement-based attachment
layer further comprises from 2.3 to 9.1 kg (5 to 20 lb) fiberglass
strands.
32. The method of claim 25 wherein the cement-based attachment
layer comprises water, cement, and space-occupying granules having
a size of less than 1 mm (0.04 inch) in the proportions of: from 29
to 35 liters (7.6 to 9.2 gallons) water; from 59.0 to 68.0 kg (130
to 150 lb) cement; and from 4.5 to 11 kg (10 to 25 lb)
space-occupying granules.
33. The method of claim 32 wherein the space-occupying granules
comprise glass microbubbles.
34. The method of claim 32 wherein the cement-based attachment
layer further comprises from 2.3 to 9.1 kg (5 to 20 lb) fiberglass
strands.
35. The method of claim 25 wherein the cement-based attachment
layer comprises water, cement, and space-occupying granules having
a size of less than 1 mm (0.04 inch) in the proportions of:
approximately 32 liters (8.4 gallons) water; approximately 63.5 kg
(140 lb) cement; and approximately to 6.8 kg (15 lb)
space-occupying granules.
36. The method of claim 35 wherein the space-occupying granules
comprise glass microbubbles.
37. The method of claim 35 wherein the cement-based attachment
layer further comprises approximately 5.4 kg (12 lb) fiberglass
strands.
Description
PARENT APPLICATION
[0001] This patent application is a Continuation-In-Part of my
previously filed patent application entitled "BUILDING BLOCK WITH A
WOODEN ATTACHMENT LAYER", U.S. Ser. No. 09/610,288, filed Jul. 6,
2000, which was a Continuation-In-Part of "BUILDING BLOCK HAVING A
WOODEN ATTACHMENT LAYER", Ser. No. 08/953,569, filed Oct. 17, 1997,
U.S. Pat. No. 6,085,480, which was a Continuation-In-Part of
"BUILDING BLOCK, METHOD FOR MAKING THE SAME, AND METHOD FOR
BUILDING A WALL USING THE SAME", Ser. No. 08/852,922, filed May 8,
1997, U.S. Pat. No. 5,913,791. All three of these previous patent
applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention generally relates to construction materials
and techniques, and more specifically relates to a building block,
a method for making the building block, and a method for building a
wall using the building block.
[0004] 2. Background Art
[0005] Building blocks have been used for centuries to construct
homes, office buildings, churches, and many other structures. Early
building blocks were hewn from stone into appropriate shapes that
were assembled together, typically using mortar, to form a wall. In
modem times, various types of concrete blocks were developed, which
are typically formed by pouring a cement mixture into a form and
allowing the cement to harden. This type of cement block is strong
and makes for a sturdy wall, but installing a traditional concrete
block requires a skilled mason that places mortar in all joints
between blocks to secure the blocks in place.
[0006] Various different block configurations have been developed
that allow mortar to be poured into inner passageways of the blocks
once the blocks have been constructed into a wall. Some of these
eliminate the need for a mason to apply mortar between the blocks
as the blocks are laid because the blocks are interlocked using
mortar poured into interior passages. Examples of blocks with inner
passages are found in U.S. Pat. No. 4,295,313, "Building Blocks,
Wall Structures Made Therefrom, and Methods of Making the Same",
issued Oct. 20,1981 to Rassias; U.S. Pat. No. 4,319,440, "Building
Blocks, Wall Structures Made Therefrom, and Methods of Making the
Same", issued Mar. 16, 1982 to Rassias; U.S. Pat. No. 2,701,959,
"Sectional Block Masonry", issued Feb. 15, 1955 to Briggs; and
Swiss Pat. No. 354237, issued Jun. 30, 1961.
[0007] One significant drawback of using concrete blocks to form
walls in a structure is that surficial covering material often
needs to be applied to the surface of the walls. Many common
surficial coverings for walls are attached using nails or screws.
For example, siding may need to be applied to the outside of the
wall, and wallboard, paneling, or other sheet material may need to
be applied to the inside of the wall. Known concrete blocks are too
hard and brittle to allow commonly-used nails or screws to be used
to attach a surficial covering material. As a result, special
concrete nails or anchors are typically used to secure wood furring
strips or studs to the concrete block wall, and the covering
materials are, in turn, fastened to the furring strips or studs.
This process of fastening wood furring strips or studs to the block
wall and nailing on the covering material to the furring strips is
time-consuming, and the concrete blocks do not hold the nails or
anchors in place very well. It is not uncommon for one or more of
the concrete nails to become loose when a surficial material is
nailed in place, compromising the structural integrity of the
wall.
[0008] Therefore, there existed a need to provide an improved
building block with an attachment layer that allows covering
materials to be directly attached to the building blocks using
conventional nails, screws, or staples.
DISCLOSURE OF INVENTION
[0009] According to the present invention, a building block has a
cement-based attachment layer on one or both exterior surfaces of
the block that can receive and hold a penetrating fastener such as
a nail, screw, staple, or the like. This allows surficial coverings
such as wallboard, siding or other materials to be easily attached
to a block wall made of the building blocks. The block includes
substantially semi-cylindrical concave portions that form a
cross-linked structure of channels when the blocks are assembled
into a wall. Once the blocks have been stacked in place in a wall,
grout or other suitable filling material is poured into the
cross-linked structure of channels. When the filling material
hardens, the blocks are locked together. Surficial covering
materials may then be nailed, screwed, or stapled directly to the
attachment layer.
[0010] The foregoing and other features and advantages of the
invention will be apparent from the following more particular
description of preferred embodiments of the invention, as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The preferred embodiments of the present invention will
hereinafter be described in conjunction with the appended drawings,
where like designations denote like elements, and:
[0012] FIG. 1 is a top view of a building block in accordance with
the present invention;
[0013] FIG. 2 is a cross-sectional view of the block of FIG. 1
taken along the lines 2-2;
[0014] FIG. 3 is a side view of the block of FIG. 1 taken along the
lines 3-3;
[0015] FIG. 4 is a perspective view of the block of FIG. 1;
[0016] FIG. 5 is a flow diagram of a method for building a wall in
accordance with the preferred embodiments using the block of FIG.
1;
[0017] FIG. 6 is a front view of a block wall in accordance with
the preferred embodiments;
[0018] FIG. 7 is top view of the wall of FIG. 6;
[0019] FIG. 8 is a flow diagram of a method for manufacturing the
block of FIG. 1;
[0020] FIG. 9 is a top view of a form for forming a large block
that is cut into small blocks like the block of FIG. 1;
[0021] FIG. 10 is a cross-sectional view of a side piece 920 of the
form assembly taken along the line 10-10 in FIG. 9; and
[0022] FIG. 11 is an enlarged view showing how the side piece 920
and end piece 930 come together for clamping as shown in the
circular area 11 of FIG. 9.
BEST MODE FOR CARRYING OUT THE INVENTION
[0023] The building block of the present invention allows any
suitable material to be directly fastened (e.g., screwed, nailed,
or stapled) to it. A cement-based attachment layer on the block
allows fasteners to be directly attached to the block.
[0024] Referring now to FIGS. 1-4, a building block 100 in
accordance with the preferred embodiment includes a first exterior
surface 110, a second exterior surface 120, a first side surface
130, a second side surface 140, a top surface 150, and a bottom
surface 160. Either or both of the first exterior surface 110 and
the second exterior surface 120 include an attachment layer 170.
For purposes of illustrating the attachment layer 170 in the
figures, attachment layer 170 in FIG. 1 is shown on exterior
surface 120. Note, however, that attachment layer 170 may be
located on either or both of the exterior surfaces 110 and 120.
[0025] Each of the side surfaces 130 and 140, the top surface 150,
and the bottom surface 160 include corresponding substantially
semi-cylindrical concave portions 135, 145, 155 and 165. In
addition, block 100 further includes a cylindrical channel 175.
These concave portions and cylindrical channel of one block align
with similar concave portions and cylindrical channels on adjacent
blocks to form a cross-linked structure of substantially
cylindrical channels when the building blocks are assembled into a
wall. These channels preferably have a circular cross-section, but
may have other geometries within the scope of the present
invention.
[0026] Block 100 is preferably comprised of a mixture of cement,
water, a wetting agent, and a suitable insulative material. The
cement is preferably Portland cement, type 1, ASTM designation C150
or similar. The preferred wetting agent is Polyheed 997, a liquid
manufactured and marketed by Master Builders Technologies, ASTM
C494, 2126 E. 5.sup.th Street, Tempe, Ariz., 85281. The term
"wetting agent" is used herein as a general term that describes a
broad category of additives for concrete that include plasticizers,
superplasticizers, and water reducers. The general function of
these additives is to act as a wetting agent, which helps the
cement and water paste in the cement mixture to adhere to the other
parts of the mixture. In the particular application for the
preferred embodiments, the wetting agent is added to assure the wet
cement mixture adequately adheres to and more completely covers the
insulative material.
[0027] The preferred insulative material is a synthetic bead
material with a suitable diameter less than 2.5 cm (1 inch), a
preferable diameter less than 1.3 cm (0.5 inch), and a most
preferred diameter of 3.2 mm (1/8 inch) to 9.5 mm (3/8 inch). The
insulative material may be any suitable insulative material, such
as polyurethane, polycyanuarate, betostyrene, etc. The preferred
insulative material is expanded polystyrene (EPS) foam beads. The
best mode of the invention uses a mixture of different bead sizes
ranging from 3.2 mm (1/8 inch) to 9.5 mm (3/8 inch). The
proportions of water, cement, wetting agent, and EPS foam beads for
the block mix are suitably 68 to 95 liters (18 to 25 gallons) water
to 150 to 190 kg (325 to 425 lb) cement to 0.24 to 0.71 liters (1
to 3 cups) wetting agent to 850 to 1400 liters (30 to 50 cubic
feet) EPS foam beads. The preferred proportions for the block mix
are 76 to 87 liters ( 20 to 23 gallons) water to 160 to 180 kg (350
to 400 lb) cement to 0.35 to 0.59 liters (1.5 to 2.5 cups) wetting
agent to 990 to 1,270 liters (35 to 45 cubic feet) EPS foam beads.
The proportions in accordance with the best mode of the invention
for the block are most preferably 81.4 liters (21.5 gallons) water
to 171 kg ( 376 lb) cement to 0.47 liters (2 cups) wetting agent to
1,080 liters (38 cubic feet) EPS foam beads.
[0028] In an alternative embodiment, class F fly ash may be
substituted for some of the concrete in the block mix. Class F fly
ash is commercially available from the Phoenix Cement Company, P.O.
Box 43740, Phoenix, Ariz., 85080. The result of using fly ash in
the block mix is a block that has a hardness at 28 days that is the
same as the block that does not contain fly ash, but that gets
harder and stronger as time goes on at a faster rate than the
regular block mix that does not contain fly ash. The proportions of
water, cement, fly ash, wetting agent, and EPS foam beads for the
block mix are suitably 68 to 95 liters (18 to 25 gallons) water to
109 to 147 kg (240 to 325 lb) cement to 31 to 45 kg (68 to 100 lb)
fly ash to 0.24 to 0.71 liters (1 to 3 cups) wetting agent to 850
to 1400 liters (30 to 50 cubic feet) EPS foam beads. The preferred
proportions for the block mix are 76 to 87 liters ( 20 to 23
gallons) water to 118 to 138 kg (260 to 305 lb) cement to 34 to 42
kg (75 to 93 lb) fly ash to 0.35 to 0.59 liters (1.5 to 2.5 cups)
wetting agent to 990 to 1,270 liters (35 to 45 cubic feet) EPS foam
beads. The proportions in accordance with the best mode of the
invention for the block are most preferably 81.4 liters (21.5
gallons) water to 128 kg (282 lb) cement to 38 kg (84 lb) fly ash
to 0.47 liters (2 cups) wetting agent to 1,130 liters (40 cubic
feet) EPS foam beads.
[0029] One suitable admixture that improves the block mix is the
addition of an air entrainer. One suitable air entrainer is a
product called Microair, which is available from Master Builders
Technologies, ASTM C494, 2126 E. 5.sup.th Street, Tempe, Ariz.,
85281. Air entrainer causes the cement to foam or bubble when being
mixed, thus causing air bubbles to be embedded (or entrained) into
the concrete mix. The addition of air entrainer into the block mix
results in the following proportions: 68 to 95 liters (18 to 25
gallons) water to 150 to 190 kg (325 to 425 lb) cement to 0.24 to
0.71 liters (1 to 3 cups) wetting agent to 850 to 1400 liters (30
to 50 cubic feet) EPS foam beads to 0.18 cu liter (0.25 to 0.75
cup) air entrainer for the block mix above with the broadest ranges
of ingredients; 76 to 87 liters ( 20 to 23 gallons) water to 160 to
180 kg (350 to 400 lb) cement to 0.35 to 0.59 liters (1.5 to 2.5
cups) wetting agent to 990 to 1,270 liters (35 to 45 cubic feet)
EPS foam beads to 0.08 to 0.16 liter (0.33 to 0.67 cup) air
entrainer for the block mix above with the narrower ranges of
ingredients; and most preferably 81.4 liters (21.5 gallons) water
to 171 kg ( 376 lb) cement to 0.47 liters (2 cups) wetting agent to
1,080 liters (38 cubic feet) EPS foam beads to 0.12 liter (0.5 cup)
air entrainer for the mix that represents the best mode of the
invention.
[0030] The best mode of the invention for the block mix includes
the proportions of water, cement, wetting agent, EPS foam beads,
and air entrainer specified above. The best mode also has a
specific order of mixing the ingredients. First, the wetting agent
is mixed into the specified quantity of water. Next, the air
entrainer is added to the water mixture and mixed in. Next, the
cement is added. The cement slurry is then mixed until most of the
large clumps of cement have been eliminated. Once the cement and
water mixture has been fully mixed, the EPS foam beads are added
and mixed thoroughly. This order of mixing has provided the best
results in practice, but this best mode of the invention does not
limit the preferred embodiments to this order. The preferred
embodiments expressly extend to any suitable order or method for
mixing the ingredients together.
[0031] In the preferred embodiment, the attachment layer 170 has a
composition that is different than the block material described
above. The preferred composition of the attachment layer 170
includes water, cement, and space-occupying granules. The term
"space-occupying granules" is not a term of art, but is a term that
is introduced herein to mean any small granule that has the
capability of interrupting the concrete mix matrix so that it
becomes less rigid and brittle. In the preferred embodiments,
space-occupying granules may have at least three different forms.
The first is granules that have a rigid or semi-rigid shell that
substantially encloses an open, hollow area. Another possibility is
granules that are substantially pliable and enclose an open, hollow
area. Yet another possibility is granules that are substantially
pliable and substantially solid. In applicant's issued U.S. Pat.
No. 5,913,791, the use of expanded polystyrene (EPS) foam beads
having a diameter of 3.18 to 9.53 mm (1/8 to 3/8 inch) is disclosed
for use in a cement-based attachment layer. EPS foam beads would
fall in the third category of space-occupying granules, those that
are substantially pliable and substantially solid. While EPS foam
beads do interrupt the concrete matrix to the point of making the
attachment layer able to receive a penetrating fastener, subsequent
tests have shown that EPS foam beads in the attachment layer do not
disperse evenly in the mix, and do not provide for a consistent
penetrating effort and holding strength. Subsequent research and
development has determined that smaller space-occupying granules
provide much more uniform penetrating and holding characteristics
for penetrating fasteners.
[0032] The preferred embodiment for the space-occupying granules is
glass microbubbles (or microspheres). These microbubbles are of the
first type listed above, namely, they have a substantially rigid
shell that encloses a substantially hollow area. These microbubbles
are readily available and are relatively inexpensive. One
commercially-available product that is suitable for use as
microbubbles is Fil-cel type 42-18 manufactured by American Stone
Pioneer, P.O. Box 4083, Rolling Hills, Calif., 90274. These
microbubbles are microscopic glass (or silica) spheres. The
microbubbles are so small that they appear as white dust to the
naked eye. Introducing the microbubbles into the concrete mix
injects minute regions of air (entrapped in the microbubbles) in
the mix, resulting in a concrete mix that is less rigid and
brittle. The purpose of the microbubbles is to change the
characteristics of the concrete mix so it can accept screws, nails,
or other penetrating fasteners, while also providing good holding
power for these fasteners. In this manner, materials may be
attached to the attachment layer 170 using standard penetrating
fasteners and conventional tools.
[0033] While the preferred materials for the microbubbles is silica
or glass, other materials could also be used to form the
space-occupying granules within the scope of the preferred
embodiments, which expressly extend to any and all materials that
create substantially enclosed spaces that are very small in size,
preferably less than 1 mm (0.04 inch) in size. In addition, the
space-occupying granules could be non-spherical shapes as well, so
long as they occupy small areas of space in the concrete mix that
will create an attachment layer capable of receiving and holding a
penetrating fastener. The space-occupying granules could also be
solid rather than a hollow bubble, which would be particularly
useful for pliable materials such as plastic or rubber materials.
The term "space-occupying granule" as used herein and in the claims
means any and all material that can occupy space in a
concrete-based mix, thereby changing the characteristics of the
concrete mix so it can receive and hold a penetrating fastener when
the mix is cured. As stated above, the preferred size for the
space-occupying granules is less than 1 mm (0.04 inch). Note that
substantially rigid granules that are substantially solid (such as
grains of sand) do not fall within the scope of space-occupying
granules disclosed herein.
[0034] For the best mode of the invention that uses glass
microbubbles, the proportions of water, cement, and microbubbles
for the attachment layer mix are suitably 26 to 38 liters (6.9 to
10 gallons) water to 54.4 to 72.6 kg (120 to 160 lb) cement to 2.3
to 23 kg (5 to 50 lb) microbubbles. The preferred proportions of
the attachment layer are 29 to 35 liters (7.6 to 9.2 gallons) water
to 59.0 to 68.0 kg (130 to 150 lb) cement to 4.5 to 11 kg (10 to 25
lb) microbubbles. The proportions in accordance with the best mode
of the invention for the attachment layer are most preferably 32
liters (8.4 gallons) water to 63.5 kg (140 lb) cement to 6.8 kg (15
lb) microbubbles. Formulating the attachment layer 170 according to
the proportions above results in an attachment layer 170 that can
receive and hold standard penetrating fasteners such as nails,
screws, and staples.
[0035] Other items such as synthetic or natural materials may be
added to attachment layer 170 to enhance its ability to hold
fasteners. Suitable synthetic materials include fiberglass, kevlar,
polypropylene, and metal wire, in any suitable form, including
filaments, fibers, strands, fabrics, powders, etc. Suitable natural
materials include cotton, hemp, flax, cellulose, animal hair,
perlite, vermiculite, etc. The proportions of these materials
depend on the characteristics of the specific material used and the
desired holding strength for attachment layer 170. For the
preferred embodiment, fiberglass strands (also known as glass
fibers) are added to the preferred attachment layer mix, resulting
in the following proportions: 26 to 38 liters (6.9 to 10 gallons)
water to 54.4 to 72.6 kg (120 to 160 lb) cement to 2.3 to 23 kg (5
to 50 lb) microbubbles to 2.3 to 9.1 kg (5 to 20 lb) fiberglass
strands for the mix above with the broadest ranges of ingredients;
29 to 35 liters (7.6 to 9.2 gallons) water to 59.0 to 68.0 kg (130
to 150 lb) cement to 4.5 to 11 kg (10 to 25 lb) microbubbles to 4.5
to 6.4 kg (10 14 lb) fiberglass strands for the mix above with the
narrower ranges of ingredients; and most preferably 32 liters (8.4
gallons) water to 63.5 kg (140 lb) cement to 6.8 kg (15 lb)
microbubbles to 5.4 kg (12 lb) fiberglass strands for the mix that
represents the best mode of the invention. The fiberglass strands
are preferably alkali-resistant, and are preferably less than 3.18
mm (1/8 inch) in diameter and less than 2.54 cm (1 inch) in length.
One example of a suitable fiberglass strand that is commercially
available is Cem-FIL, available from Cem-FIL International, The
Parks, Newton-Le-Willows, Mercyside WA120JQ England.
[0036] In addition to adding synthetic or natural materials to
attachment layer 170 as described above, the formulation of the
attachment layer 170 may be improved by adding one or more
admixtures to the attachment layer mix. Examples of suitable
admixtures include air-entrainers (such as those compliant with
ASTM C 260), bonders (such as latex, polyvinyl chloride, polyvinyl
acetate, acrylics, or butadiene-styrene copolymers), plasticizers,
superplasticizers, and the like. Many materials (such as those
listed above) may improve the ability of attachment layer 170 to
hold fasteners in place, and their addition to the mix for
attachment layer 170 is within the scope of the preferred
embodiments.
[0037] Note that the ranges specified herein are believed to be
workable ranges for the various ingredients in the block mix.
However, it is possible that certain combinations within the ranges
specified would not produce a block with the desired strength.
Different formulations within the specified ranges are possible
that will produce different properties of the resultant block.
[0038] Referring now to FIGS. 5-7, a method 500 for building a wall
600 using a plurality of blocks 100 begins by stacking the blocks
(step 510). Block 100 is designed so that a wall is built by
putting down a first course (or row) 610 of blocks end-to-end
without mortar, then stacking the second course of blocks 620 on
the first course of blocks without mortar in staggered fashion so
that each block in the second course overlaps two blocks in the
first course. Referring to FIGS. 1-4, with blocks 100 stacked to
form a wall as shown in FIG. 6, the concave portions 135 and 145 of
corresponding side portions 130 and 140 of a block in the course
above are aligned above cylindrical channels 175 in the blocks
below, and the concave portions 135 and 145 of corresponding side
portions 130 and 140 of the lower blocks are aligned below the
cylindrical channel 175 of the blocks above.
[0039] Note that if the blocks have a single attachment layer on
one exterior surface (110 or 120), the attachment layer 170 of each
block must be aligned with the side of the wall where the
attachment layer is needed during the stacking of the blocks in
step 510. Of course, if an attachment layer 170 is present on both
exterior surfaces 110 and 120, no such alignment is required.
[0040] During the stacking of the blocks 100, various items may be
placed within the cross-linked structure of channels as required
(step 520). For example, electrical cable, water and waste pipes,
gas pipes, and reinforcing steel bar (known as rebar) may be put
within the channels. These channels provide natural passageways for
routing these items to their desired locations. Openings from the
channels to the exterior of the block may be made using a drill,
router, saw, or any other suitable tool to accommodate the exit
points for plumbing, electrical wires, and the like. Note that
excessive items within these channels may compromise the structural
integrity of the wall if they significantly reduce the amount of
filler material in the channel. As a result, it may be preferable
to have only rebar in the channels, and to run all electrical
cables and pipes in recesses cut in the surface of the block.
[0041] Once two or more courses are stacked in place, with the
desired rebar, cable, and/or pipes in place within the channels, a
suitable filler material is then poured into the exposed openings
at the top of the blocks (step 530). The preferred filler material
is a cement-based grout that has a plastic consistency that allows
it to flow by the force of gravity to fill all of the channels in
the blocks. The grout material is referred to herein as a plastic
material, not because the grout contains any plastic, but because
the grout, when wet, has plastic properties. Suitable grout
typically has a slump of 20-25 cm (8-10 inches). The best mode
formulation for the grout is 299 kg (658 lb) cement to 170 kg (375
lb) water to 1,270 kg (2800 lb) aggregate, where the aggregate is
preferably 75% sand and 25% pea gravel no greater than 1.3 cm (1/2
inch) in diameter. Note that the consistency of the filler material
must allow the filler material to flow around all items located in
the channels. Of course, many suitable filler materials other than
grout may be used within the scope of the present invention. For
example, a variety of injected foam, plastic, adhesive, or epoxy
compounds would be suitable filler materials. In the preferred
method of constructing a wall using blocks 100, the blocks for the
entire wall are stacked in place (step 510) and all of the required
items are routed in the channels (step 520) before the filler
material is added (step 530). In this manner the filler material
need only be poured once after all of the blocks for the wall are
in place (as shown by the arrows in FIG. 6), rather than by pouring
at different levels as the wall goes up.
[0042] Building a block wall 600 in accordance with method 500
requires corner blocks 730 that are different than the block 100 of
FIG. 1 that is used in the middle of wall 600. These differences
must be present to ensure that the resulting cross-linked structure
of substantially cylindrical channels is closed within the wall 600
so that there is no open access from the channels to outside the
wall, except for the openings at the top of the wall. A closed
system will assure that no filler material that is poured into the
network of channels will spill out. As a result, as the filler
material fills the channels, the pressure from the material causes
the filler material to fill the voids in the channels. As shown in
FIG. 7, the semi-cylindrical concave portions of the corner blocks
730 do not extend from one side of the block to the other, but make
a right-angle turn toward the adjacent wall. Corner blocks 730 have
the same width and height as block 100, and have a preferred length
that is the sum of the width of the block plus half the length of
the block. In the preferred embodiment, block 100 has a width of 28
cm (11 inches), a height of 40.6 cm (16 inches), and a length of
122 cm (48 inches), so corner block 730 has a width of 28 cm (11
inches), a height of 41 cm (16 inches), and a length of 89 cm (35
inches).
[0043] After the filler material is poured in place (step 530), it
is allowed to harden and cure (step 540). Once the filler material
has cured, any suitable surficial covering material may be attached
to the exposed attachment layer 170 using any suitable fastener
that at least partially penetrates attachment layer 170 (step 550).
For example, if the interior side of an exterior wall 600 has an
attachment layer 170, any suitable wall material (such as wallboard
and paneling) may be directly nailed, stapled, or screwed to the
attachment layer 170. Likewise, if the exterior side of an exterior
wall has an attachment layer 170, any suitable exterior covering
material (such as siding) may be directly nailed, stapled, or
screwed to the attachment layer 170. Allowing a wall covering
material to be directly fastened to wall 600 using standard
fasteners eliminates the time and expense of furring out the walls
with wood members.
[0044] Referring now to FIGS. 8-11, a method 800 for forming a
block 100 (of FIG. 1) starts with a form 900 as shown in FIG. 9.
The first step in method 800 is to assemble the form (step 810).
The assembly of the form can be understood with reference to FIGS.
9-11. Form 900 has a bottom portion 910, side portions 920, and end
portions 930. Each of these portions 910, 920, and 930 of form 900
are all preferably coated with a non-stick substance to ensure that
the block does not stick to the form. Examples of suitable nonstick
coatings include wax, form oil, teflon, or other form release
agents.
[0045] Side portions 920 are pivotally coupled to the bottom
portion 910 to allow the side portions 920 to pivot away from the
bottom portion 910. The pivoting action of the side portions 920
with respect to the bottom portion 910 is shown in the
cross-sectional view of FIG. 10. Note that the features at the end
of portion 920 in the direction of the cross section 10-10 (such as
the angle portion 940, the clamp 950, and the end portion 930) are
not shown in FIG. 10 for the purpose of clarity. In the specific
implementation in FIG. 10, a portion of right-angle material 1010
runs along the length of side portion 920 and under the bottom of
side portion 920 and part of bottom portion 910. Right angle
material 1010 is used to reinforce the side portion 920 and the
bottom portion 910 to assure these do not bend while the block is
being formed. Right angle material 1010 is preferably angle iron,
but could be any suitable material with the requisite stiffness and
strength to reinforce side portion 920 and bottom portion 910. In
the specific implementation in FIG. 10, right angle material 1010
is fixedly coupled to the side portion 920. A hinge 1020 has a
first tab 1030 that is fixedly coupled to the bottom portion 910,
and a second tab 1040 that is fixedly coupled to the right angle
material 1040. In this manner the right angle portion 1010 and side
portion 920 can pivot away from the bottom portion 910, as shown in
FIG. 10 in phantom. Any suitable manner known in the art may be
used to attach the right angle material 1010 to the side portion
920, to attach the hinge tab 1040 to the right angle material 1010,
and to attach the hinge tab 1030 to the bottom portion 910,
including nails, screws, adhesives, welding, etc. In the preferred
implementation, side portion 920 and bottom portion 910 are 3/4
inch form plywood that is treated for contacting concrete, and
right angle material 1010 is screwed into the side portion 920,
hinge tab 1040 is screwed to right angle material 1010, and hinge
tab 1030 is screwed to bottom portion 910.
[0046] When the form is being assembled in step 810, the side
portions 920 are pivoted to a substantially right angle position
with respect to the bottom portion 910, as shown by the solid
representation of side portion 920 in FIG. 10. Once the side
portions are in place, the end portions can then be positioned and
clamped in place. FIG. 11 is an enlargement showing the assembly of
corner portion 11 in FIG. 9. End portions 930 are separate pieces
from side portions 920 and bottom portion 910. The end portions 930
are preferably as high as the side portion 920, and wide enough to
span beyond side portions 920 to the edge of the right angle corner
pieces 940, as shown in FIG. 11. Right angle corner pieces 940 are
fixedly attached to side portion 920, and run along the height of
side portion 920. An end piece 930 is positioned next to the side
piece with its corresponding right angle corner piece 940, and is
pressed against the right angle corner piece 940. Referring to FIG.
9, a C-clamp 950 is then used to attach the end portion 930 to the
right angle corner piece 940, as shown in three of the corners in
FIG. 9. A C-clamp is preferably placed at the bottom and at the top
of the end portion 930 at each corner, which means that each end
portion 930 is secured to the two side portions using four
C-clamps. Note that a square is preferably used when performing the
clamping operation to assure that side portions 920 are square with
respect to bottom portion 910.
[0047] With the form now assembled, the blocks in accordance with
the preferred embodiments may be made. Referring again to FIG. 8,
the attachment layer material is then mixed (step 820). The
ingredients and proportions of the attachment layer material are
provided above. Once thoroughly mixed, the attachment layer
material is placed along the bottom portion 910 of the form (step
822). In the preferred embodiment, a layer of thin plastic is
placed along the bottom portion 910 of the form to inhibit the
attachment layer from sticking to the bottom portion 910. Many
different thicknesses of plastic may be used, but experience has
shown that 2 mil plastic provides the most satisfactory results.
The attachment layer material is then compressed to remove air
pockets and leveled in the form (step 824). This compression can be
done in a variety of ways. One suitable way uses a tool referred to
as a "tamper" that has a flat surface parallel to the ground with a
handle extending upwards. A person takes the tamper, raises it up
and forces it down on the block material, forcing out all voids and
air pockets. Of course, other techniques, including automated
techniques, could also be used to compress the block material.
[0048] Next, the block material is mixed (step 830). The
ingredients and proportions of the block material are provided
above. Once thoroughly mixed, the block material is poured into the
form (step 832). Once the block material is poured in the form, the
block material is compressed to eliminate voids and air pockets
(step 834). This compression may be done using a tamper or using
any suitable manual or automated technique. Once compressed, the
block material is leveled to the desired block height (step 836).
In the preferred embodiments, the block material is "screeded off",
as is common in working with concrete, using a board or other
straight edge to scrape off the excess block material to a depth of
28 cm (11 inches) of block material remaining in the form. Once the
block mix is leveled, a lid is placed on the block material, and
the block material is allowed to cure (step 840). The purpose of
the lid is to avoid drying the surface of the block mix before it
has adequately cured, and practical experience shows that using the
lid provides a more strong and uniform surface on the block than
blocks that cure without a lid. Of course, the lid is optional, and
curing without a lid is within the scope of method 800.
[0049] Other steps may also be performed within the scope of the
preferred embodiments. For example, after the lid is placed on the
block material, one or more braces can be placed to pull the side
portions 920 together, to assure the large block does not bulge.
One suitable brace is a length of lumber with a slot that has a
length that fits over the side portions 930 of the form to
precisely space the side portions of the form from each other.
Another suitable brace is a metal tube with perpendicular members
attached to its end with the same spacing. In this manner the width
of the large block is precisely controlled, providing better
consistency between different batches of blocks. Of course, other
steps could also be performed with the process steps in method
800.
[0050] Once the block is cured, the form is disassembled, and the
block is removed from the form (step 850). Note that this block is
a big block, from which several of the blocks in FIG. 1 may be
made. The large block is now cut into several small blocks (step
860). In the preferred embodiment, form 900 has interior dimensions
of 122 cm (48 inches) by 249 cm (98 inches) by 36 cm (14 inches)
deep. The form is 36 cm (14 inches) deep because the block material
is not compressed when initially poured into the form. Once
compressed, the block material is screeded off to leave 28 cm (11
inches) of block material. The large blocks that come out of the
form are thus 122 cm (48 inches) wide by 249 cm (98 inches) long by
28 cm (11 inches) thick. In the preferred embodiments, the large
block is cut across its width in 41 cm (16 inch) widths, resulting
in 6 blocks out of each 98 inch large block that are each 41 cm (16
inches) high, 28 cm (11 inches) wide, and 122 cm (48 inches) long.
In the preferred embodiment, the large block is placed on a roller
table and is fed through a set of five saw blades that cut the
block of material into six equal portions, each of which becomes a
single block as shown in FIGS. 1-4.
[0051] Next, the channels must be formed in each small block (step
870). Referring to FIG. 2, one suitable way to form the
semi-cylindrical channels 135 and 145 and the cylindrical channel
175 is to place block 100 in a hydraulic press that pushes three
sharpened steel pipes through the block. One of these pipes cuts
channel 135, another cuts channel 175, and the last cuts channel
145. Once these channels are formed, the block is then pushed into
a chute that has two sharpened steel pipes to cut the top channel
155 and the bottom channel 165. Of course, other methods for
forming the channels are within the scope of the preferred
embodiments, including drilling, sawing, routing, forming, or any
other method that could be used to form these channels.
[0052] In the best mode of the invention, the size of the channels
in block 100 is as follows: the diameter of the cylindrical channel
175 is 15 cm (6 inches); the vertical semi-cylindrical concave
portions 135 and 145 each have a diameter of 15 cm (6 inches); and
the horizontal semi-cylindrical concave portions 155 and 165 each
have a diameter of 10 cm (4 inches). The dimensions of block 100
allow a wall to be quickly and efficiently constructed, and the
dimensions of the channels help assure that filler material will
flow around any items (such as pipe, rebar, cables, etc.) that are
placed within the channels.
[0053] Note that the units herein are expressed in both metric and
English units, so this patent application can be prosecuted in
foreign jurisdictions that require metric units without changes to
the specification. The preferred embodiments are implemented in
English units, and any variation between the stated English units
and their metric equivalents is due to rounding errors, with the
English units being the more correct measurement of the two.
[0054] While the invention has been particularly shown and
described with reference to preferred embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
spirit and scope of the invention. For example, a block may be made
in a variety of different sizes. In addition, the size, number and
geometries of the channels 175 and concave portions 135, 145, 155
and 165 may vary from that disclosed herein.
* * * * *